rear pulley lip broken???
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Stage III
Joined: Sep 2016
Posts: 3
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From: ohio
rear pulley lip broken???
I'm new here and to Harley I got a problem with my rear drive belt pulley. I got a new tire put on and accidentally dropped it and bent the lip of the pulley. I tried to straighten it and it broke the lip! Can I just smooth out the broken spot with a die grinder and run it? I have been told this would be OK because the lips are not what holds the belt on and the belt should run true on the pulley even with out the lip? I know it should be replaced but I don't have the cash for another one right now. Looking for advice?
Extreme HDF Member
Joined: Sep 2010
Posts: 14,744
Likes: 402
From: Phoenix '53, '88, '09 Big Twins
pulleys are cheaper than belts...replacing the belt requires pulling the complete primary drive AND removing the swingarm.
a big job
depending on which year and model you have a pulley could be cheap and available on the aftermarket- the guys who buy billet everything will have a cheap pulley in the garage
( and you need NEW bolts on a pulley swap)
physics pushes the belt to the outside rim of the pulley when moving forward--- when the bike is pushed backward the pulley moves to the inside- it never tracks in the middle
Mike
a big job
depending on which year and model you have a pulley could be cheap and available on the aftermarket- the guys who buy billet everything will have a cheap pulley in the garage
( and you need NEW bolts on a pulley swap)
physics pushes the belt to the outside rim of the pulley when moving forward--- when the bike is pushed backward the pulley moves to the inside- it never tracks in the middle
Mike
Last edited by mkguitar; Sep 29, 2016 at 11:21 AM.
Road Master
Joined: Jul 2015
Posts: 1,249
Likes: 565
From: Utah
I'm sorry to say it, but you should replace that pulley. If you don't, you will end up with some kind of problem at the most inconvenient time, probably a belt issue.
FWIW, you are in good company here with breaking things during reassembly. My dear wife turns music on in the house at a higher volume so she and my son can't hear the language coming from the garage whenever I work on the bike.
FWIW, you are in good company here with breaking things during reassembly. My dear wife turns music on in the house at a higher volume so she and my son can't hear the language coming from the garage whenever I work on the bike.
Road Master
Joined: Mar 2010
Posts: 934
Likes: 54
From: SE Wisconsin
These guys make a good point but, how big of a missing piece are we talking about?
Chances are it is not big enough to ever be an issue, especially if you deburr the edges like you mentioned and keep an eye on it for a while.
Chances are it is not big enough to ever be an issue, especially if you deburr the edges like you mentioned and keep an eye on it for a while.
Road Master
Joined: Aug 2005
Posts: 1,203
Likes: 7
From: Bedford , Pa
look for a used one. I just bought a new one for my 06 Electra Glide and it was $350. I have my old one the teeth on it is rough in spots but was working fine. Dealer replaced it as warranty but I installed it myself
Road Warrior
Joined: Nov 2014
Posts: 1,962
Likes: 140
From: NY
AGREE.
As long as a lrg portion of outer lip didnt break off there should be enough lip on pulley left before & after where break is located to support the belt just fine.
Just ensure to use some 400 -600 grit sandpaper to smooth out edges in the area where the break is thats facing the belt & could contact it to ensure it doesnt cut/chaf or prematurely wear the belt.
Also ensure you look cloas at rear pulley in area of break with a strong/bright light to ensure there are no stress cracks coming from the area of the break weakening it that could lead to a major pulley failure with it cracking & falling apart while your riding which wouldnt be good.
If you see no cracks coming from area of the break and have sanded the rough break area to smooth it out take a 4-5 mile ride and pull over to look at belt to see if its being marked or worn in any way,esp on edge facing the break in pulley lip.
If belt looks marked or worn go home and get a new pulley.
But if belt looks ok continue the test ride for another 15-20 miles and get into a little bit to stress things.
Then if that turns out ok seeing no marks/wear on the belt post 15-20 miles take then continue on test for another 40-50 miles and chk it again.
If it looks ok after that with no visible wear or marks on the belt you should be ok.
But to be safe i'd rec you still give the belt & pulley a once over every so often over the next few few k miles to ensure nothing crops up like wear on edge of belt or new cracking/splitting of the pulley showing up.
Thats what i'd do if it was my bike and if the pulley did fine till next rear tire replacement maybe that would be the time to replace it.
BTW,If you dont want to be bothered with the test rides & or keeping an eye on it after that if test rides come out ok then for piece of mind i'd rec you replace the pulley & forget about it.
Scott
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Stage III
Joined: Sep 2016
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From: ohio
Thanks for all the input the broken piece is maybe an inch it is over 2 teeth on the sprocket. I have sanded it and smoothed it and i'm thinking as long as everything is in line it should be ok. It is a 1997 Electra glide by the way
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Extreme HDF Member
Joined: Sep 2010
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From: Phoenix '53, '88, '09 Big Twins
for the evo EG, the 70T ( tooth) pulley is like $50 used.
your model may also be able to use the 65T pulley ( 40315-94 from a softail) which will give a slight over drive...this swap requires that you have about 3/4" on your adjuster from where you are now- that'll give a rough idea.
on my '95 I would run the 70T when I was in town and when preparing for a multi-week tour I would swap to the 65T for the overdrive.
as I said at the beginning a pulley costs a LOT less than a belt- and replacing your belt is a big job
the belt will tolerate a hole in the middle, but a tear at the edge will spread
you are new to HD, we want this to be a happy experience, not frustrating
mike
your model may also be able to use the 65T pulley ( 40315-94 from a softail) which will give a slight over drive...this swap requires that you have about 3/4" on your adjuster from where you are now- that'll give a rough idea.
on my '95 I would run the 70T when I was in town and when preparing for a multi-week tour I would swap to the 65T for the overdrive.
as I said at the beginning a pulley costs a LOT less than a belt- and replacing your belt is a big job
the belt will tolerate a hole in the middle, but a tear at the edge will spread
you are new to HD, we want this to be a happy experience, not frustrating
mike
Last edited by mkguitar; Sep 29, 2016 at 01:58 PM.
